Water drainage systems

ABSTRACT

Synthetic rocks are used as a substitute for natural gravel to fill in around perforated drain tiles in a water drainage system. The synthetic rocks may be of a size and shape that mimics the natural rock they replace, but they are preferably significantly lighter in weight. The synthetic rocks may alternatively be tubular or cubic shaped, for example, and may include one or more lumens or other passageways to facilitate the flow of water through and/or around the rocks.

FIELD OF THE INVENTION

The present invention relates generally to materials and methods for use in water drainage systems, and more particularly to materials and methods effective for use with perforated drain tiles to provide water drainage from a building.

BACKGROUND TO THE INVENTION

The usage of drain tiles to direct water away from a building, and thus to prevent water from seeping into the building, has been known for many years. Commonly, perforated or slotted drain tiles are placed in a trench around the inside and/or outside perimeter of a building to form a pipe line which relieves hydrostatic pressure by collecting and diverting water away from the building, such as to a storm sewer. Such systems are frequently referred to as French drain tile systems.

The drain tiles comprise perforated or slotted pipe sections with sufficient perforations or slots to collect and divert water. The tiles are typically located in a bed of river rock, gravel or crushed stone (referred to collectively in this disclosure as natural gravel, rock, or stone), which allows water to flow into the tiles and keeps dirt from clogging the perforations/slots. The gravel also provides a supporting substrate for concrete, etc., that may be added to cover the drain tiles from above.

While the use of gravel to surround the drain tile provides advantages in terms of allowing good water flow and the ability to hold the tile in place, it also has disadvantages. For example, because the amount of gravel used in a particular job is large, heavy equipment such as dump trucks and front loaders are generally required to transport and handle the stone. In addition, transporting the gravel around the job site (e.g., into a basement) requires substantial physical labor and adds significant cost to the job.

A need therefore exists for materials and methods for utilizing perforated drain tiles to provide water drainage from a building, without requiring the use of heavy gravel to surround the tile. The present invention addresses that need.

SUMMARY OF THE INVENTION

Briefly describing one aspect of the present invention, there is provided a method of waterproofing a basement by providing perforated drain tile in a trench around the inside perimeter of a building, and filling in around the tile with lightweight, synthetic rocks. In another aspect of the invention synthetic rocks appropriate for that purpose are provided, with such rocks preferably including one or more passageways to facilitate the flow of water through a bed of the synthetic rocks. Long nails or pins may be used to help hold the perforated tile in place.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows one embodiment of a drainage trench with synthetic rock and perforated tile.

FIG. 2 shows one embodiment of a synthetic rock that may be used in the methods of the present invention.

FIG. 3 shows another embodiment of the synthetic rocks that may be used in the methods of the present invention.

FIG. 4 shows another embodiment of the synthetic rocks that may be used in the methods of the present invention.

FIG. 5 shows another embodiment of the synthetic rocks that may be used in the methods of the present invention.

FIG. 6 shows another embodiment of the synthetic rocks that may be used in the methods of the present invention.

FIG. 7 shows another embodiment of the synthetic rocks that may be used in the methods of the present invention.

FIG. 8 shows another embodiment of the synthetic rocks that may be used in the methods of the present invention.

FIG. 9 shows another embodiment of the synthetic rocks that may be used in the methods of the present invention.

FIG. 10 shows another embodiment of the synthetic rocks that may be used in the methods of the present invention.

FIG. 11 shows another embodiment of the synthetic rocks that may be used in the methods of the present invention.

FIG. 12 illustrates one method of providing a drainage trench with synthetic rock and perforated tile.

FIG. 13 shows one method of using synthetic rocks to replace natural rock to fill in around drainage tile.

FIG. 14 shows a section of semi-rigid material overlaying synthetic rock surrounding drain tile in one embodiment of the present invention.

FIG. 15 shows another view of the embodiment of FIG. 14.

DETAILED DESCRIPTION OF THE INVENTION

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to certain embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications of the illustrated embodiments being contemplated as would normally occur to one skilled in the art to which the invention relates.

As indicated above, one aspect of the present invention relates to the use of lightweight, synthetic rocks or pellets to fill in around a length of perforated drainage tile. In one preferred embodiment, the drain tile is being used in a basement waterproofing system. The synthetic rocks support the drainage tile in a manner in which water is free to flow into the tile. In the preferred embodiment mentioned above, the synthetic rocks also provide a substrate on which, for example, concrete may be poured to repair the floor. The synthetic rocks function much as natural rock would in a similar environment, but are far easier to transport and install.

In another aspect of the invention, synthetic rocks appropriate for use in the disclosed method are disclosed. Such rocks are sized and shaped to fill in around perforated drain tile, and may include one or more openings or passageways to facilitate the flow of water through a bed of the rocks.

As to the synthetic rocks that may be used in one or more aspects of the invention, the synthetic rocks may be of substantially any shape and size effective to fill in around a drainage tile, although synthetic rocks that simulate natural gravel are preferred for certain applications. In some preferred embodiments the synthetic rocks may be tubular shaped, such as is shown in FIGS. 13 through 15. Synthetic rocks of different shapes and/or sizes may be used together, and in some cases synthetic rocks may be used with natural rock. The synthetic rocks may function as a filler material to fill in around drainage tiles and to facilitate the flow of water into and through the tiles.

In some embodiments the synthetic rocks are generally tubular, while in other embodiments the synthetic rocks are cubic or pyramidal shaped. In some embodiments the synthetic rocks are irregularly shaped, much as natural rock is. The synthetic rocks need not replicate the look of natural rock, so long as the synthetic material can function generally as natural rock would when used to fill in around train tiles.

In some embodiments the synthetic rocks have at least one hole (which may be referred to as an opening, an aperture, or a lumen) extending through the rock to permit water to flow through, and not just around, the rock. In some preferred embodiments two, three or more holes are provided through the synthetic rocks. In other embodiments the synthetic rocks have other passageways or open spaces to facilitate the flow of water around and/or through the rock.

In some preferred embodiments the largest dimension of the synthetic rocks is less than 1 inch, most preferably between 0.5 inches and 1.0 inch. In other preferred embodiments the synthetic rocks have a largest dimension of less than 3 inches, more preferably between 0.5 and 2 inches, and most preferably between 0.5 and 1.5 inches. In other embodiments the largest dimension of the synthetic rocks is greater than 3 inches.

It is to be appreciated that the term “synthetic rock” is used herein to refer to synthetic pieces of any appropriate size, regardless of whether the natural material would be referred to as a rock or a pellet or a stone, or some other name. No distinction is intended between synthetic rocks and synthetic pellets or synthetic stones or synthetic gravel, etc. All such materials are intended to be included in the term synthetic rock.

The synthetic rocks may be made of any one or a combination of synthetic materials, and different materials may be used together in a single application. In general though, the synthetic rocks are made of a material that is lightweight, yet strong enough to substitute for natural gravel in waterproofing applications. Examples of synthetic materials include, but are not limited to, polyethylenes, polypropylenes, polystyrenes, polyvinyl chlorides, polyurethanes, polycarbonates, acrylics, polyethylene terephthalates, polyamides, polyesters, acrylonitrile butadiene styrenes, polyvinylidene chlorides, synthetic rubbers, etc.

The drain tile may be perforated or slotted drain tile such as is conventionally used in basement waterproofing applications. Drain tile diameters are typically between about 2 and 6 inches in diameter, and preferably about 4 inches in diameter, although larger or smaller drainpipes may be used. While drain tiles are commonly referred to as perforated or slotted, the tiles may have opening of virtually any size and shape effective for allowing water to enter radially and flow through the tile. For the purposes of this disclosure, the term “perforated drain tile” is understood to refer generally to drain tiles having perforations, slots, or other openings that allow water to flow radially into the tile. Also, in this disclosure perforated drain tile may alternatively be referred to as perforated drainpipe.

It is also to be appreciated that the term drain tile as used herein refers to any drain tile, pipe or tubing that may be used to direct a flow of water, such as in basement waterproofing applications. The drain tile, pipe or tubing may be rigid, or it may be flexible, and it may be provided in substantially any length and diameter appropriate for a particular application.

To illustrate one method for practicing the invention, a drainage trench may be dug below the floor around the inside perimeter of a building. Alternatively, a trench may be provided around the outside perimeter of a building, or at other location desired to be protected from water. As is known to the art, when a trench is dug inside an existing structure it is common that a portion of the existing floor (generally concrete) will first need to be removed.

The trench may be of substantially any dimensions, but is commonly about 6-18 inches deep and 6-18 inches wide, most commonly about 12 inches deep and 12 inches wide. The length is generally determined by the size of the area to be protected. In most cases the trench is dug to a depth near, but not below, the depth of the bottom of the building foundation.

The drainpipe is laid in the trench. One, two, or more lengths of drain tile may be laid adjacent to or on top of each other.

In some embodiments the drainpipe may be laid on top of a base layer of synthetic gravel. When a base layer of synthetic gravel is used, the base layer is typically between 1 and 4 inches in depth.

Pins, nails, brackets, etc., may be used to hold the drainpipe in place.

Additional synthetic rock may be provided on top of and around the drainpipe. This top layer of synthetic gravel may comprise the same synthetic gravel that was used in the base layer (if a base layer was used), or it may be different. The top layer is typically provided so that it fills in around the drainpipe. The top layer may also cover the drainpipe, most commonly to a depth of 1 to 4 inches.

Concrete or other solid flooring material may then be provided over the synthetic rock to provide an appropriate floor. The concrete is preferably poured to a depth of at least three or four inches.

Referring now to the drawings, FIG. 1 shows one embodiment of a drainage trench with synthetic rock and perforated tile, as disclosed in one aspect of the present invention. Trench 11 is provided in soil 12 after removing a portion of concrete floor 13. In the illustrated embodiment trench 11 is adjacent footer 14 which supports foundation wall 15. Two lengths of perforated drain tile 16 are provided in trench 11. Synthetic rocks 17 are provided over drain tile 16. A section of vinyl Cove Mold 18 overlays at least a portion of synthetic rocks 17. Replacement concrete floor 19 is provided over synthetic rocks 17 and over vinyl cove mold 18.

FIG. 2 shows one embodiment of a synthetic rock appropriate for use in the present invention. Synthetic rock 20 includes side wall 22 and interior walls 24 defining passageways 23 through the rock. The dimensions of the illustrated embodiment may vary depending on the desired use, but generally in one preferred embodiment the diameter “d” of the rock is between 0.5 inches and 2.0 inches and the length “l” of the rock is a similar size. The largest dimension of such rocks is therefore between about 0.5 inches and about 3 inches, with the largest dimension preferably being between about 0.7 inches and about 1.5 inches.

FIG. 3 shows one embodiment of a synthetic rock appropriate for use in the present invention. Synthetic rock 30 includes side wall 32 and interior walls 34 defining passageways 33 through the rock.

FIG. 4 shows one embodiment of a synthetic rock appropriate for use in the present invention. Synthetic rock 40 includes side wall 42 and interior walls 44 defining passageways 43 through the rock.

FIG. 5 shows one embodiment of a synthetic rock appropriate for use in the present invention. Synthetic rock 50 includes side wall 52 and interior walls 54 defining passageways 53 and 55 through the rock.

FIG. 6 shows another embodiment of a synthetic rock appropriate for use in the present invention. Synthetic rock 60 includes side walls 64 and interior walls 62 defining passageways 63 and 65 through the rock.

FIG. 7 shows another embodiment of a synthetic rock appropriate for use in the present invention. Synthetic rock 70 includes a combination of rectangular and/or triangular and/or trapezoidal walls defining a shell that may or may not include passageways through the rock.

FIG. 8 shows another embodiment of a synthetic rock appropriate for use in the present invention. Synthetic rock 80 again includes a combination of rectangular and/or triangular and/or trapezoidal walls 82 cooperating with inner wall 84 to define passageways 83 through the rock.

FIG. 9 shows another embodiment of a synthetic rock appropriate for use in the present invention. Synthetic rock 90 again includes a combination of rectangular and/or triangular and/or trapezoidal walls 92 cooperating with inner wall 94 to define passageways 93 and 95 through the rock.

FIG. 10 shows another embodiment of a synthetic rock appropriate for use in the present invention. Synthetic rock 100 again includes a combination of rectangular and triangular and/or trapezoidal walls cooperating with an inner wall to define a passageway 105 through the rock.

FIGS. 11A and 11B illustrate another embodiment of a synthetic rock appropriate for use in the present invention. The synthetic rock includes irregular shaped walls which may cooperate with an inner wall to define a passageway through the rock.

Illustrating now one method of practicing the present invention, as shown in FIG. 12 a drainage trench 121 is dug below the floor 123 around the inside perimeter of a building 125. A portion of the existing concrete floor 123 has been removed. The illustrated trench is about 12 inches deep and 12 inches wide.

One or two courses of drainpipe 126 are laid in the trench. Additional lengths of drain tile are laid end-to-end to connect the various pieces of drainpipe if necessary, or fewer, longer pieces of drainpipe may be used. Pins or nails 130 may be used to hold the drainpipe in place. This is particularly helpful if the drain tile is a longer piece of lightweight plastic, and if the drain pipe is to be bent around corners, etc.

Synthetic rock 127 is then provided on top of and around the drainpipe, preferably filling in around the drainpipe. The illustrated layer of synthetic rock covers the drainpipe to a depth of about 3 or 4 inches.

A semi-rigid supporting layer such as Cove Mold 128 is used to overlay at least a part of the synthetic rock. Concrete or other solid flooring material 129 is then provided over the synthetic rock to provide an appropriate floor. The concrete is preferably poured to a depth of at least three or four inches.

FIG. 13 shows a drainage trench with a portion of the trench being filled with drainpipe and natural rock, and a portion of the trench being filled with drainpipe and synthetic rock. As can be seen from the illustration, the synthetic rock performs at least as well, while providing the advantages of being significantly easier to transport and install.

FIG. 14 shows a drainage trench that has been filled with drainpipe and synthetic rock. In this embodiment the synthetic rock comprises 100 pound psi ABS tubing that has been cut into sections approximately 1 to 3 inches in length. Cove Mold has been used to cover a portion of the trench before new concrete is poured. FIG. 15 shows another view of the embodiment of FIG. 14, particularly showing a finished corner before new concrete is poured.

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that all changes and modifications that come within the spirit of the invention are desired to be protected. 

1. In a method of utilizing perforated drain tiles to help direct a flow of water, wherein said perforated drain tiles are at least partially surrounded by a layer of natural gravel that has been positioned immediately around said drain tiles to facilitate water flow into and through said drain tiles, the improvement comprising substituting synthetic rocks for said natural gravel.
 2. The method of claim 1 wherein said synthetic rocks are lightweight synthetic rocks that weigh less than 5 pounds per cubic foot of installed synthetic rock.
 3. The method of claim 1 wherein at least some of said synthetic rocks comprise a generally tubular member having an outer diameter of between 0.5 inches and 2.0 inches.
 4. The method of claim 3 wherein said synthetic tubular members have a length of between 0.5 inches and 2.0 inches.
 5. The method of claim 1 wherein at least some of said synthetic rocks have at least one lumen therethrough.
 6. The method of claim 1 wherein at least some of said synthetic rocks have at least one two lumens therethrough.
 7. The method of claim 1 wherein at least some of said synthetic rocks have at least one three lumens therethrough.
 8. The method of claim 1 wherein at least some of said synthetic rocks comprise a generally tubular member having an outer diameter of between 0.5 inches and 2.0 inches, a length of between 0.5 inches and 2.0 inches, and at least one lumen therethrough.
 9. A method of augmenting perforated drain tile for draining water, said method comprising providing a trench adapted to facilitate water flow, providing drain tile in said trench, and providing synthetic rocks around at least a portion of said drain tile to prevent flow-restricting material from filling said trench.
 10. A method of preventing water from seeping up through the floor of the lower level of a building, said method comprising: a) providing a trench below the level of the floor of a building; b) providing perforated or slotted drain tile in said trench to provide a pathway for draining water from the building; c) filling in around at least a portion of said drain tile with a synthetic filler material sized and configured to facilitate the drainage of water into and through said drain tile; and d) providing a solid flooring material over said synthetic filler material.
 11. The method of claim 10, and further including the step of providing a semi-rigid support material over said synthetic filler material before providing the solid flooring material.
 12. The method of claim 10 wherein said synthetic filler material is tube-shaped, and has a length of less than about 2 inches. 